Instruction/ maintenance manual of the product GREENSTAR 24i junior Bosch
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TH E APP LIANC E I S FO R US E WITH NA TU RAL GAS OR L.P .G . (C at II 2H3P TYP E C1 3 & C33) NA TU RAL GAS: WORC E STER G R E E N ST AR 24i junior GC NU M B E R 4 7 -3 1 1-86 WORC E STER G R E E .
SYMB OLS US E D I N TH I S MAN UAL: WOR C E STE R : TEC H N I CAL: 08 705 26624 1 SE RVI C E: 0845 7 256206 SP AR ES: 0 1 905 7525 7 1 LITE RA TU R E: 0 1 905 752556 TRAI N I N G: 0 1 905 752526 SALES: 0 1 905 752640 WE B S ITE: www .worcester-bosch.co.
SAFET Y & RE G UL A TION S SAFETY P R EC AUTION S & S YM B OLS 3 I NST ALLA TI ON R E G U LA TIO NS 3 APPL IA NCE INFORMA TIO N G E N E RAL I N F OR MA TI ON 4 T ECHNI CA L D A T A 5 LA Y OUT .
S AFE TY PRECA UTIONS & I NST ALLA TIO N R E G U LA TIO NS IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 3 SAFET .
GENER A L INF ORM A T IO N ST AN DARD P ACK AGE: A - W all hung gas fired condensing combi boiler for central heating and domestic hot water B - Boiler support frame C - Hardware literature pack D - B.
T ECHNI CA L D A T A IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 5 T ECHNIC A L D A T A APPL IANC E INFO RMA TI ON Domestic Hot Water Min. heat input KW 7 .38 7 .38 9.
LA Y OUT & C O M P O N E NTS The diagram opposite shows the controls in the servicing position and excludes the outer case. 1 AI R / GAS MANI FO LD 2F A N 3 AI R / GAS AD J USTME NT S CR EW 4G A S.
LA Y OUT & C O M P O N E NTS 10 PLA TE T O PLA TE DHW HE A T EX CH A NGER 3 2 S Y S TEM PUMP 36 FL O W T URBINE 37 U N USE D PO RT 38 AUT O AI R VE NT 39 FL O W CONNEC TION FROM BOIL ER HE A T EX .
C LE AN I NG P R I MAR Y S YS TE MS BEFO RE CL EA NING T HE S Y S TEM : E NS U R E TH E S Y STEM AN D P I PEWOR K I S IN GOO D W ORKIN G ORD ER KEEP THE EXI S TIN G BOIL ER/ CIRCUL A TIN G PUMP WHERE POS SIBL E OR USE A PO WE R FL USHI NG M A CH IN E T O AI D TH E C LEAN SI N G PR OC E D U R E B E FO R E I NST ALLI N G A N EW B OI LE R .
MA I NS SUPPL Y ELECT RIC SUPPL Y : • Supply: 230V - 50Hz , 1 40 watts • C able: PVC insulated 0.75mm 2 (24 x 0.2mm) temperature rated to 90°C . • Ex ternal 3A fuse to B S1 362. • The appliance must be earthed. • I PX4D. N OTE: this is reduced to IP20 if the following mechanical timers are fitted: 7 7 1 6 1 92 036 or 7 7 1 6 1 92 037 .
W A TE R S Y STE M S & PI PEWO R K PLA STIC PI PEW ORK: • Any plastic pipework must have a polymeric barrier with 600mm (minimum ) length of copper or steel pipe connected to the boiler .
CONDE NSA TE PIPEW ORK CONDE NSA TE PI PEW ORK: • The condensate pipe must be a minimum of 22mmØ plastic pipe. • The condensate pipework must fall at least 50mm per metre t owards the out let and should take t he shortest pract icable route. • The pipework must follow one of the options shown opposite into an internal serviceable trap (min .
PRESSU R E RELIE F PIPEW OR K PRESSU RE RE LIEF PIPEWORK: • The pressure relief drain pipe (M ) from the boiler should be at least 1 5mm diameter copper pipe and run downwards away from any electrics or other hazard, preferably to an external drain or soakaway.
B OI LE R L OC A TIO N & C LEAR ANC ES IN ST ALLA TIO N & SE RVICI NG I NSTR UCTIONS FO R WORC ESTER G RE E NST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 13 PR E - IN ST ALLA TION B .
B OI LE R L OC A TIO N & C LEAR ANC ES IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 14 PR E - IN ST ALLA TION 1 .
PLU M B I NG MAN I F OLD CO N N ECTI ON S: Heating System: 22mm compression fittings DHW: 1 5mm compression fittings Gas: 22mm compression fittings Use the fittings supplied in the Lit/ Hardware pack. • If the boiler pipes are to be run behind the appliance ensure that the pipes pass through the slot in the yellow plastic guide (A ).
PR E - IN ST ALLA TION FLU E TE R M I NAL P OS ITI O NS • The flue must be fitted and terminated in accordance with the recommendations of B S5440 : Part 1 . • The flue must not cause an obstruction. • Discharge and any noise from the flue outlet must not cause a nuisance.
FLU E O PTIO N S INST ALLA TI ON & SE RVIC ING I NSTR UCTION S FOR WOR CESTER G R EE NST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 17 PR E - IN ST ALLA TION FLU E OPTI O NS • The diagrams (opposite) show the components used and the maximum flue length for each configuration of 1 00mm and 1 25mm flues .
I I M P ORT ANT: All the previous P re-Installation sections must be read and requirements met before starting boiler or flue installation. E F A B C C D G U N P AC KI N G WALL FRAM E AN D ANC I LLAR .
W ALL MO U NTI N G PLA TE FLU E OP ENING INST ALLA TI ON & SE RVIC ING I NSTR UCTION S FOR WOR CESTER G R EE NST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 19 IN ST ALLA TION CO MMISSI ONIN G SAF ETY : All relevant safety precautions must be undertaken .
4 7 6 U N P AC K I N G TH E AP P LIANC E U N P AC KI NG TH E AP P LIANC E A - Outer carton B - Inner sleeve (unwraps from front ) C - Packaging base D - Protective wrapping E - Appliance outer case F - Protective inner packaging 4 . Remove outer carton (A ) and place safely away from the working area .
A E D B BOIL ER CO NNEC TI ONS IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 21 IN ST ALLA TION Handling Hole Do not lift by the air gas manifold.
BOIL ER CO NNEC TI ONS IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 22 IN ST ALLA TION BOIL ER CO NNEC T ION S CAUTIO N: IS OLA TE TH E MAI N S GAS SU P PL Y B E FO R E ST ARTI NG ANY WOR K AN D OB S E RVE ALL R E LEV ANT SAFETY PRECAU TIONS .
FLU E I NST ALLA TI ON IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 23 IN ST ALLA TION FLU E I N ST ALLA TI O N HORI.
FLU E I NST ALLA TI ON IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 24 IN ST ALLA TION FLU E I N ST ALLA TI O N M EA.
FLU E I NST ALLA TI ON IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 25 IN ST ALLA TION A B C D E A - Standard Flue B.
CONDE NSA T E CONNECTION : Never terminat e or discharge into any open source, including; sink, bat h, shower, bidet, toilet et c . Note: any external condensate pipework should be protected with weather resistant insulation to help prevent freezing. • Ensure that the condens ate drain is 22mm diameter plastic pipe.
E LE CTR I C S A 1 2 B E LECTR IC S IN ST ALLA TION & S ERVI CI NG I NSTRU CTIONS FO R WORCESTE R GR E EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 27 IN ST ALLA TION CAUTIO N: IS OLA.
POSIT ION OF WIRE D COMPON E NT S CO MMISSI ONIN G POSIT ION OF WI R ED COMPON ENT S IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 .
PRE-COM MISSION I NG CHEC KS IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 29 COMMISSIONING A E B C D 22mm 1 5mm 22mm.
FI LLI NG TH E SY STEM IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 30 CO MMISSI ONIN G FI LLI N G TH E S Y STE M 1 T urn on the water main and open the system valves.
A D F C B G E H I Switching the appliance on/off: 1 T urn on mains power supply T urn on any external controls Set the thermostatic radiator controls to maximum temperature Set the clock/progr.
W A TE R TR E A TM E NT EN S U RE THA T TH E SYSTEM HAS BEEN CL EANED AS O N P AGE 8 OF THESE IN STR UCTION S. FLUS H I NG (Cent ral Heating ) : 1 Switch off the boiler (A). Open all drain cocks (B) and drain the system (C ) while the appliance is hot.
CO MMIS SI ONING THE C OM B USTIO N FOR TH E AP PLIANC E IS F ACT OR Y SET . NO ADJ USTM E NT IS R EQU IR E D IF TH E GAS IN LET P RE S SU R E IS C OR R ECT .
FINI SHIN G C OMMI SS IONIN G IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 34 CO MMISSI ONIN G FINI SHIN G C OMMI SSI ONING The boiler has been factory set , so there should be no need to adjust any cont rols.
I N SP E CTI ON AN D SE RVIC E T o ensure the continued efficient operation of the appliance it must be chec ked at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage. However , an annual service is recommended .
I N SP E CTI ON AN D SE RVIC E Component Access 1. Removing outer case 1. Remove bottom panel by pulling it forward and off. 1.1 Undo and remove 2 screws (A) securing boiler casing at the top of the appliance. 1.2 Undo but do not remove the 2 screws (B) securing boiler casing at the b ottom of the appliance.
I N SP E CTI ON AN D SE RVIC E Setting Boiler to Maximum. NOTE: W hen running in the service mode, the boiler will operate both the Central Heating and DHW circuits . This is to allow sufficient time for the setting procedure. It will be necessar y to run water through the DHW circuit to ensure that the boiler will not cycle on low heating demands.
I N SP E CTI ON AN D SE RVIC E T o Clean the Heat Exchanger 1 W ith outer case and base panel removed and the power isolated from the appliance, remove the cover panel (A) by removing the retaining screw (B). 2 Remove clip (C) from gas valve outlet. Pull gas adjustment assembly (D) free from the plastic connection on the gas valve.
I N SP E CTI ON AN D SE RVIC E 4 Remove electrical connector from fan. 5 Undo and remove securing nut (E) from the top of the heat exc hanger . 6 Remove stainless steel viewing mirror (F). 7 Rotate fan and air/gas manifold assembly ( G) around the top of the heat exc hanger until it stops at the lug.
Q I NS P ECTI ON AN D S E RVI C E IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 40 SERV ICING & SP ARES I N SP E CTI ON AN D SE RVIC E 9 L M N 0 P R 9 Remove burner (L).
C A UTION: TUR N OF F TH E GAS S U P PL Y AN D I SOLA TE TH E MAI N S S U P PLI E S B E FOR E ST ARTI NG ANY WOR K AN D OBS E RVE ALL R E LEV ANT SAF ETY P R ECAUTIONS.
R E P LACE M E NT O F P ARTS 5. Moving boiler control to service position 5.1 Remove screw (A) securing control. 5.2 Gently pull forward. 6. Gas valve Isolate gas supply at boiler gas cock. 6.1 Remove wire clip from gas valve outlet then pull gas adjustment assembly free from plastic connector and pull forward clear of case.
R E P LACE M E NT O F P ARTS 9. Access to boiler control components Remove 3 screws (A) and remove cover from control. 10. PCB fuse Remove fuse F1(B) from the PCB and replace. There is a spare fuse clipped into the underside of the electrical cover .
12.3 R E P LACE M E NT O F P ARTS 12. Replacing control The contr ol is supplied within its plastic housing. The complete unit must be r eplaced. Remove ALL electrical connections from the control PCB including where cables run through restraints.
R E P LACE M E NT O F P ARTS 13. Air / gas manifold and fan assembly Remove electrical connector from fan. Remove wire clip from gas valve outlet then pull gas adjustment assembly free from plastic connector and pull clear of case (see 6.1). 13.
R E P LACE M E NT O F P ARTS 15. Fan 15.1 Remove 3 screws (A) retaining mixing chamber . 15.2 Remove 2 screws (B) retaining the fan to the air/gas manifold. 15.3 Remove screw (C) retaining plate and remove. Re-assemble with new fan ensuring seals are correctly fitted.
R E P LACE M E NT O F P ARTS 19. Diverter valve motor Insure the appliance is in service mode (there is no need to drain the appliance). Disconnect the electrical connector from the diverter valve motor . 18.1 Pull the motor assembly (A) towards you.
R E P LACE M E NT O F P ARTS 23. Pump head Ensure the boiler is fully drained (see draining the appliance). Disconnect the electrical connection from the bottom of the pump. 23.1 Remove the four Allen bolts (A) securing the pump at each corner .
R E P LACE M E NT O F P ARTS 27 . Hydraulic Block Ensure the appliance has been fully drained (see draining the appliance). Disconnect the electrical connections to the NT C, T urbine and pump.
R E P LACE M E NT O F P ARTS 29. Plastic protection device Ensure the system is fully drained (see draining the appliance). Disconnect all pipes connected to the pump housing. Remove the electrical connection to the pump. W ithdraw the metal clip to the right of the pump head to release the pump housing.
R E P LACE M E NT O F P ARTS 31. Bypass valve Remove the Hydraulic block from the boiler (See Removing the Hydraulic Block). 31.1 Remove the two spring clips at either end of the copper bypass pipe.
33. Setting the CO 2 Note: When running in the service mode, the boiler will operate both the central heating & DHW circuits . This is to allow sufficient time for the setting procedure. It will be necessary to run water through the DHW circuit to ensure that the boiler will not cycle on low heating demands.
SH O RT P ARTS LIST 1 Fan WORCE ST ER P ar t No . 8 7 1 7 204 453 0 GC No. H26 536 2 Burner WORCE ST ER P ar t No . 8 7 1 8 1 20 609 0 GC No. H26 538 3 Gas valve NG WORCE ST ER P ar t No . 8 7 1 6 1 0 7 052 0 NG GC No. H26 540 LPG WORCES TER P art N o.
1.1 1.2 A 2.2 2.3 2.1 3 C B TH E GAS / AIR R A TIO M U ST BE R ES ET AFTE R C ONVE R S IO N. TH E PR OCED URE CA N BE FOUND IN TH E R E PLAC E M E NT P ARTS SE CTIO N OF TH I S MAN UAL.
F A UL T F INDING IN ST ALLA TIO N & SE RVICI NG I NSTRU CTIONS FO R WORC ESTER G RE EN ST AR 24 i junior/28 i junior 8 716 10 7 33 6b (11/05) 55 FA U L T F I N D I N G & DIAGR AMS Off On Slow.
CEN TR A L HEA T IN G FUNC T ION NO YE S PO WER SWITCH ON CE NTRAL HE A T IN G DE MAN D Fan to start speed. Diverter valve in CH position Pump ON. IG N ITI ON SEQUENCE (see detail) BL UE LIG HT ON BURNER LIT? GREEN FLAM E LIG HT ON Stop spark. W ait 10 seconds 5th attempt? L OCKOUT 10 second stabilisation period.
W ait 5 seconds IG N ITI ON SEQUENCE (see detail) PR E H E A T AN D DHW F U N CTI ON NO YE S PO WER SWITCH ON T ap open (recognised by flow turbine) Diverter valve in DHW position Pump ON.
PRO TEC TION FU NC TION Boiler temperature below 8°C Run autofroststat function Pump antiseize Pump run 5 seconds every 24hrs PR O TECTI ON F U N CTIO N IN ST ALLA TIO N & SE RVICI NG I NSTRU CTI.
CONTROLS T o comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME & TEMPERA TURE CONTROL TO HEA TING ROOM T/ST A T & PROGRAMMER/TIMER PROGRAMMA.
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below . Service Provider. Before completing the appropriate Service Interval Record below , please ensure you have carried out the service as described in the boiler manufacturer ’s instructions.
EXCE LL E NCE C OM E S AS ST AN DARD W orcester, Bosch Group Cotswold W ay, W arndon, W orcester WR4 9SW . T el. 019 05 754 624 Fax. 01905 75 4619 W orcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. www .worcester-bosch.co.uk 8 7 1 6 1 0 7 336b ( 1 1 .
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